U.S. patent application number 12/163807 was filed with the patent office on 2009-02-12 for loading apparatus.
Invention is credited to John Cash, III, Michael Flagg, Rafe Patterson.
Application Number | 20090038274 12/163807 |
Document ID | / |
Family ID | 40345206 |
Filed Date | 2009-02-12 |
United States Patent
Application |
20090038274 |
Kind Code |
A1 |
Cash, III; John ; et
al. |
February 12, 2009 |
LOADING APPARATUS
Abstract
A loading apparatus for loading blister cards into sleeves
includes a blister card magazine for receiving a stack of blister
cards and a sleeve magazine for receiving a stack of sleeves. A
loading conveyor moves a lug along a path to load a blister card
into a sleeve. A gate releasably retains the sleeve in a loading
position as the blister card is loaded into the sleeve. The loading
apparatus also includes a hopper that facilitates loading sleeves
into the sleeve magazine and sensors that ensure the blister cards
are properly loaded into sleeves.
Inventors: |
Cash, III; John; (Dallas,
GA) ; Patterson; Rafe; (Fortson, GA) ; Flagg;
Michael; (Newnan, GA) |
Correspondence
Address: |
MEADWESTVACO CORPORATION;ATTN: IP LEGAL DEPARTMENT
1021 MAIN CAMPUS DRIVE
RALEIGH
NC
27606
US
|
Family ID: |
40345206 |
Appl. No.: |
12/163807 |
Filed: |
June 27, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60955264 |
Aug 10, 2007 |
|
|
|
Current U.S.
Class: |
53/493 ;
53/284.5 |
Current CPC
Class: |
B65B 43/44 20130101;
B65B 35/44 20130101; B65B 5/106 20130101 |
Class at
Publication: |
53/493 ;
53/284.5 |
International
Class: |
B65B 57/00 20060101
B65B057/00; B65B 43/44 20060101 B65B043/44 |
Claims
1. An apparatus for engaging inserts and sleeves, comprising: a
first magazine configured to stage inserts, comprising a first
support surface that is positioned along a segment of a path; a
second magazine adjacent the first magazine, the second magazine
being configured to stage sleeves, comprising a second support
surface that is positioned along a segment of the path; and at
least one lug that is configured to move along the path so as to
propel a predefined number of the inserts into engagement with a
lowermost sleeve.
2. The apparatus of claim 1, wherein the second magazine is
downstream of the first magazine with respect to a direction of
movement of the at least one lug along the path.
3. The apparatus of claim 1, wherein the at least one lug is driven
by a conveyor.
4. The apparatus of claim 1, further comprising a metering
structure positioned to permit no more than the predefined number
of the inserts to be propelled into engagement with the lowermost
sleeve.
5. The apparatus of claim 4, the metering structure being
positioned between the first magazine and the second magazine.
6. The apparatus of claim 4, the metering structure being adjacent
at least one of the first support surface and the second support
surface.
7. The apparatus of claim 2, wherein the first support surface is
raised with respect to the second support surface to align the
predefined number of the inserts with an opening in the lowermost
sleeve.
8. The apparatus of claim 1, further comprising a sensor positioned
to detect a target on the lowermost sleeve or a lowermost insert;
wherein at least one of the first support surface and the second
support surface is positioned and configured to define a gap
through which the sensor can access the target.
9. The apparatus of claim 8, wherein the sensor is mounted at an
angle with respect to the plane of the path, and at least one of
the first support surface and the second support surface is
disposed at a corresponding angle so as to expose the gap for
access by the sensor.
10. The apparatus of claim 9, wherein the distal end of the at
least one lug is shaped and positioned to conform to the angle the
at least one of the first support surface and the second support
surface that is angled.
11. The apparatus of claim 2, further comprising a gate that is
positioned adjacent the downstream end of the second magazine.
12. The apparatus of claim 11, wherein the gate is configured and
positioned in relation to the path so as to stabilize a sleeve as
the predefined number of the inserts is propelled into the
sleeve.
13. The apparatus of claim 11, wherein the gate is configured and
positioned in relation to the path so to releasably retain a sleeve
in the second magazine.
14. The apparatus of claim 11, wherein the gate comprises a device
selected from the group consisting of: rollers, and electronically
controlled mechanical stoppers.
15. The apparatus of claim 1, the at least one lug being configured
to move along the path at a variable speed based at least in part
on its position in relation to the lowermost sleeve.
16. The apparatus of claim 1, further comprising: a hopper
configured to supply the second magazine with sleeves; a supply
conveyor comprising a trailing plate and a leading plate, the
supply conveyor being configured to transfer a carton of items from
the trailing plate to the leading plate to overturn a carton of
items; and a back pressure apparatus for moving an overturned
carton of items from the leading plate onto the hopper.
17. The apparatus of claim 16, wherein the hopper comprises a
conveyor; and wherein the back pressure apparatus and the conveyor
are controlled to move stacks of sleeves toward the second
magazine.
18. The apparatus of claim 16, wherein the back pressure apparatus
comprises a conveyor and at least one lug.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application No. 60/945,894, filed Jun. 28, 2007, and U.S.
Provisional Application No. 60/955,264, filed Aug. 10, 2007, the
entirety of which are herein incorporated by reference.
TECHNICAL FIELD
[0002] This invention relates generally to packaging machines and,
more specifically, to apparatuses for loading blister cards into
sleeves.
BACKGROUND
[0003] Blister card packages are known in the art, and are
particularly useful for enclosing pills and other individual doses
of medication in an arrangement that is child-resistant but
promotes compliance with a prescribed regimen. One aspect of the
blister card inserts is the fragility of the blisters, which
usually include a clear substrate with blisters enclosed by a foil
film. To protect the blisters from inadvertent release of the
contents and undesirable access by children, a blister card is
commonly packaged by being inserted into a protective sleeve.
[0004] It is desirable to make use of high speed automated
packaging technology to load the blister cards into sleeves.
However, it is critical that loading errors be minimized to prevent
waste, and more importantly, to ensure that unsafe packages are not
delivered to users. Accordingly, there is a need for an apparatus
that can assemble packaging arrangements efficiently, while
ensuring that the packages are properly assembled to achieve the
protective and safety objectives of the packaging design.
SUMMARY
[0005] The various embodiments of the present invention overcome
the shortcomings of the prior art by providing an apparatus for
engaging elements of a package. For example, in a first embodiment,
the apparatus is configured to package inserts and sleeves. In
other embodiments, the apparatus is configured to combine a top and
a base of a structure, primary and secondary packaging, an inner
structure and an outer structure, combinations thereof, and the
like.
[0006] The first embodiment of the apparatus includes a first
magazine that is configured to stage a stack of inserts and a
second magazine that is adjacent to the first magazine. The second
magazine is configured to stage sleeves. The first magazine
includes a first support surface that is positioned along a segment
of a path and the second magazine includes a second support surface
that is positioned along a segment of the path. In certain
embodiments, the first surface is raised with respect to the second
surface to align the predefined number of inserts with an opening
in the lowermost sleeve. In such embodiments, the second magazine
can be positioned downstream of the first magazine with respect to
the direction of movement of the lug along the path.
[0007] The apparatus further includes a lug that is configured to
move along the path. In certain embodiments, the lug is driven
along the path by a conveyor and the magazines include a gap
through which the lug travels along an operational portion of the
path. Along the operational portion of the path, the lug combines a
sleeve and a predefined number of the inserts. For example, the lug
can propel the lowermost insert into engagement with the lowermost
sleeve.
[0008] According to one aspect of the disclosure, the apparatus
includes a metering structure that restricts the number of inserts
that exit the first magazine. In the first exemplary embodiment,
the metering structure is positioned to permit no more than the
predefined number of inserts to be propelled into engagement with
the lowermost sleeve. The metering structure is positioned between
the first magazine and the second magazine and is adjacent to the
support surfaces of the magazines.
[0009] According to another aspect of the disclosure, a sensor is
positioned to detect a target on a lowermost sleeve or a lowermost
insert. The sensor can access the target through the gap or through
another opening. Where the sensor accesses the target through a gap
or opening in the lower end of the magazines, the sensor can be
mounted at an angle with respect to the plane of the path and the
support surfaces are disposed at a corresponding angle so as to
expose the gap for access by the sensor. In such embodiments, the
distal end of the lug is shaped and positioned to conform to the
angle of the support surfaces. For example, as a quality control
measure, the loading apparatus is configured such that a bar code
sensor can read a barcode on the lowermost blister card prior to
the lowermost blister card being loaded into the lowermost sleeve.
Specifically, the plane that is perpendicular to the lowermost
blister card is at an acute angle with respect to the plane in
which the lugs travel. Other quality control measures include a
sensor that verifies that the orientation of each sleeve is correct
prior to loading, a mechanism that cooperates with a sensor to
verify that the orientation of each blister is correct prior to
loading, cameras or proximity sensors that determine when the
magazines are empty, sensors that verify each sleeve is loaded with
a blister pack, and sensors that verify each blister pack is locked
within a sleeve. It should be noted that, as used herein, the term
sensor refers to any suitable detection device including but not
limited to cameras; motion, sound, heat light, and pressure sensing
devices; and the like.
[0010] The apparatus further includes a gate that is positioned
adjacent to the downstream end of the second magazine. The gate is
configured and positioned in relation to the path to stabilize a
sleeve as an insert is propelled into the sleeve. Alternatively
described, the gate is configured and positioned in relation to the
path to releasably retain a sleeve in the second magazine. The gate
can be actively controlled or passive. For example, the gate can be
a device such as a displaceable roller or an electronically
controlled mechanical stopper. In certain embodiments, the speed
and position of the lug are synchronized with the open and closed
positions of the gate. Also, the lug can be configured to move
along the path at a variable speed based at least in part on its
position in relation to the lowermost sleeve.
[0011] The loading apparatus also includes a hopper that
facilitates loading the second magazine with sleeves and a supply
assist apparatus that adds groups of sleeves, initially contained
in cartons, to the sleeves on the hopper. The supply assist
apparatus includes a supply conveyor, and a back pressure
apparatus. The supply conveyor includes a trailing plate and a
leading plate and is configured to transfer a carton of items from
the trailing plate to the leading plate to overturn the carton of
items. Once the carton of items is overturned on the leading plate,
the back pressure apparatus moves the overturned carton of items
from the leading plate to the hopper. In certain embodiments, the
hopper includes a conveyor that moves the sleeves toward the upper
end of the downstream magazine. In such embodiments, the back
pressure apparatus moves overturned cartons onto the conveyor. Both
the back pressure apparatus and the conveyor can be controlled to
move stacks of items in a flow direction. The back pressure
apparatus can include a lug that moves in the flow direction along
an operation portion of a path.
[0012] The foregoing has broadly outlined some of the aspects and
features of the present invention, which should be construed to be
merely illustrative of various potential applications of the
invention. Other beneficial results can be obtained by applying the
disclosed information in a different manner or by combining various
aspects of the disclosed embodiments. Accordingly, other aspects
and a more comprehensive understanding of the invention may be
obtained by referring to the detailed description of the exemplary
embodiments taken in conjunction with the accompanying drawings, in
addition to the scope of the invention defined by the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a partial perspective view of a loading apparatus,
according to an exemplary embodiment of the disclosure.
[0014] FIG. 2 is a perspective view of a package that includes a
sleeve and a blister card, according to an exemplary embodiment of
the disclosure.
[0015] FIGS. 3 and 4 are exploded views of the package of FIG.
2.
[0016] FIG. 5 is a partial perspective view of the loading
apparatus of FIG. 1.
[0017] FIG. 6 is a partial cross sectional side elevation view of
the loading apparatus of FIG. 1.
[0018] FIG. 7 is a partial cross sectional plan view of the loading
apparatus of FIG. 1.
[0019] FIG. 8 is a partial end elevation view of the loading
apparatus of FIG. 1.
[0020] FIGS. 9 and 10 are cross-sectional views of a blister card
magazine of the loading apparatus of FIG. 1.
[0021] FIG. 11 is a perspective view of a metering block of a the
loading apparatus of FIG. 1.
[0022] FIG. 12 is a partial perspective view of a hopper and a
supply assist apparatus of the loading mechanism of FIG. 1.
[0023] FIG. 13 is a partial cross sectional side elevation view of
a loading apparatus, according to an alternative exemplary
embodiment of the disclosure.
DETAILED DESCRIPTION
[0024] As required, detailed embodiments of the present invention
are disclosed herein. It must be understood that the disclosed
embodiments are merely exemplary of the invention that may be
embodied in various and alternative forms, and combinations
thereof. As used herein, the word "exemplary" is used expansively
to refer to embodiments that serve as illustrations, specimens,
models, or patterns. The figures are not necessarily to scale and
some features may be exaggerated or minimized to show details of
particular components. In other instances, well-known components,
systems, materials, or methods have not been described in detail in
order to avoid obscuring the present invention. Therefore, specific
structural and functional details disclosed herein are not to be
interpreted as limiting, but merely as a basis for the claims and
as a representative basis for teaching one skilled in the art to
variously employ the present invention.
[0025] Referring now to the drawings, wherein like numerals
indicate like elements throughout the several views, the drawings
illustrate various aspects of exemplary embodiments of a loading
apparatus. The illustrated embodiments of the loading apparatus are
configured to load blister cards into sleeves to form packages
although it is contemplated that the teachings described herein can
be applied to combine, engage, or otherwise package other items.
For example, the exemplary loading apparatus can be adapted to load
inserts into sleeves, to load cartons with items, to combine parts
of a structure, and the like.
[0026] Referring to FIG. 1, a first embodiment of a loading
apparatus 10 includes a blister card magazine 12 for receiving a
stack of blister cards 14 (FIGS. 3 and 4), a sleeve magazine 16 for
receiving a stack of sleeves 18 (FIGS. 2-4), plates 20a, 20b for
supporting the blister cards 14 and sleeves 18 in the parallel
magazines 12, 16, a loading conveyor 22 with lugs 24 attached
thereto for loading the lowermost blister card 14 into the
lowermost sleeve 18, and a gate 26 that retains the lowermost
sleeve 18 in a loading position as the lowermost blister card 14 is
loaded therein and releases the lowermost sleeve 18 from the
loading position thereafter. Alternative configurations of gates 26
illustrated in FIGS. 5 and 6 include a spring-loaded roller
mechanism described in further detail below. Continuing with FIG.
1, the loading apparatus 10 includes a hopper 27 that feeds the
sleeves 18 into the sleeve magazine 16, a supply assist apparatus
28 (shown in FIG. 11) that loads groups of sleeves 18 onto the
hopper 27, and a finishing conveyor 29 that moves the loaded
sleeves 18, for example, to a labeler (not shown). In addition,
devices such as cameras, proxy sensors, and other sensors provide
quality control. The loading apparatus 10 is described in further
detail below.
[0027] The terms "upstream", "downstream", "trailing", and
"leading" are used herein with respect to a flow direction and a
path, such as a flow direction F1 and a path P1 associated with the
lugs 24. The terms can be used to describe the direction of
movement of elements or to describe the relative position of
elements with respect to one another. Specifically, the terms
"upstream" and "downstream" can refer to elements having fixed
positions, for example, where a downstream element is positioned at
a distance in a flow direction from an upstream element. Downstream
movement is movement in a flow direction and upstream movement is
movement opposite a flow direction. Further, the terms "leading"
and "trailing" can refer to elements that are moving in the flow
direction, for example, where the leading element is further along
in a flow direction than the trailing element.
[0028] The terms "longitudinal" and "transverse" are used herein to
describe movement or alignment with respect to a flow direction or
to a path. Specifically, the term longitudinal can be used to
describe movement or alignment with a flow direction or a path and
the term transverse can be used to describe movement or alignment
that is substantially perpendicular to a flow direction or a
path.
[0029] The terms "lower," "lowermost," "upper," and "uppermost" are
used herein to describe the relative vertical positions of elements
in the magazines 12, 16, particularly in relation to the conveyor
surface.
[0030] Referring now to FIGS. 2-4, the illustrated sleeve 18 and
the illustrated blister card 14 are described in further detail.
Referring particularly to FIGS. 3 and 4, the illustrated sleeve 18
is formed from a base portion 30 and a top portion 32 that are
attached to one another, as shown in FIG. 2. Specifically, the base
portion 30 and the top portion 32 are connected to one another as
pegs 34 are press fit in hollow cylinders 36. However, in
alternative embodiments, it is contemplated that the sleeve 18 can
be a unitary structure or that the portions 30, 32 can be
alternatively connected to one another. Furthermore, those skilled
in the art will appreciate that the sleeve can be from more than
two portions.
[0031] The illustrated sleeve 18 includes a top wall 40, a base
wall 42, and opposing outer side walls 44a, 44b that are configured
as a tubular structure. One end of the tubular structure is
enclosed by an end wall 46 and the other end is a substantially
open end 48. In the illustrated embodiment, the open end 48 is
dimensioned such that the sleeve 18 only receives a blister card 14
that is properly oriented with respect thereto. The sleeve 18
includes a compartment 50 that is dimensioned to receive the
blister card 14 and to align the blister card 14 within the sleeve
18. In the illustrated embodiment, inner side walls of the
compartment 50 are ribs 52a, 52b that are inwardly offset from the
outer side walls 44a, 44b. The compartment 50 is further provided
by the top wall 40, the base wall 42, and the end wall 46.
[0032] The illustrated sleeve 18 includes an element of a locking
mechanism that releasably locks the blister card 14 within the
sleeve 18. Specifically, the sleeve 18 includes a protrusion 54
that projects into the compartment 50 from the base wall 42. The
protrusion 54 is adjacent the end wall 46 and is shaped so as not
to obstruct a leading edge E1 of the blister card 14 as the blister
card 14 is received in the compartment 50. Specifically, the
protrusion 54 includes a sloped surface 56 that faces the open end
48 of the sleeve 18.
[0033] The sleeve 18 also includes a release mechanism to release
the elements of the locking mechanism from one another. In the
exemplary embodiment, the release mechanism is a push flap 60 that
is separated from the top wall 40 by a U-shaped slot 62 so as to be
pivotally displaceable into the compartment 50. The push flap 60 is
disposed in the base wall 42 between the protrusion 54 and the end
wall 46. The sleeve 18 may optionally include a retainer structure
64, positioned near the open end 48, to prevent complete removal of
the blister card 14 from the compartment 50.
[0034] Generally described, the illustrated sleeve can be
substituted with another outer structure such as a shell or carton
that is configured to receive an inner structure such as a blister
card, insert, or product. In alternative embodiments, the sleeve is
formed from a paperboard blank. As mentioned previously, the
illustrated loading apparatus can be alternatively configured to
accommodate other blister cards and sleeves or other structures
that are to be combined.
[0035] Continuing with FIGS. 3 and 4, the illustrated blister card
14 is described in further detail. The illustrated blister card 14
includes a planar substrate 70 and a plurality of blisters 72 that
are arranged in rows. The blisters 72 typically hold one or more
medicaments or other items (not shown). The blister card 14 can
include, for example, a tray, which is a plastic sheet in which the
blisters 72 are formed, that is attached to a paperboard card such
that the planar substrate 70 includes laminated layers of plastic
and paperboard and such that items are enclosed in the recesses
provided by the blisters 72. Alternatively, a foil backing can be
attached to the tray.
[0036] The blister card 14 includes an element of the locking
mechanism. In the illustrated embodiment, the element is an
aperture 74 that is dimensioned and positioned to receive the
protrusion 54. The compartment 50 is dimensioned with respect to
the blister card 14 such that, when the blister card 14 is received
in the compartment 50, the aperture 74 is positioned or aligned to
receive the protrusion 54.
[0037] The illustrated blister card 14 includes a bar code B, which
is printed on or otherwise applied to the planar substrate 70 to
identify the product contained in the blister card 14. It should be
understood that any code or symbol could alternatively be used and
read by a sensor, as described in further detail below. The blister
card 14 also includes a chamfered corner C that ensures that the
blister card 14 is properly oriented in the blister card magazine
12, as described in further detail below.
[0038] The blister cards 14 can be alternatively configured and/or
formed according to alternative methods. For example, referring
momentarily to FIGS. 6-10, the illustrated blister cards 14 include
an alternative number of rows and columns of blisters 72. As
another example, the blister cards 14 can taper or narrow towards
the leading edge E1 to facilitate loading the blister cards 14 into
the sleeves 18.
[0039] Referring to FIGS. 1 and 5-7, the loading apparatus 10 is
described in further detail. The blister card magazine 12 and the
sleeve magazine 16 are substantially parallel to one another and
have open upper ends 80, 82 in which the blister cards 14 and
sleeves 18 are loaded, respectively. Lower ends 84, 86 of the
blister card magazine 12 and the sleeve magazine 16 are partially
closed by the plates 20a, 20b. The plates 20a, 20b are positioned
at the lower ends 84, 86 to align and support the lowermost blister
card 14 and the lowermost sleeve 18 along the operational portion
of the path P1 of the distal ends of the lugs 24. Specifically, the
lowermost blister card 14 and the lowermost sleeve 18 are aligned
and supported on upstream and downstream support surfaces 90, 92,
respectively. In the illustrated embodiment, the upstream and
downstream support surfaces 90, 92 are the upper surfaces of the
plates 20a, 20b. Referring to FIGS. 6 and 8, the upstream support
surface 90 is raised with respect to the downstream support surface
92 so as to align the lowermost blister card 14 with respect to the
open end 48 of the lowermost sleeve 18. The upper end 82 of the
sleeve magazine 16 extends to the hopper 27, which loads sleeves 18
therethrough, as described in further detail below.
[0040] The blister card magazine 12 is dimensioned to receive the
blister cards 14 and to arrange the blister cards 14 in a stack
that is supported by the upstream support surface 90. Similarly,
the sleeve magazine 16 is dimensioned to receive the sleeves 18 and
to arrange the sleeves 18 in a stack that is supported by a
downstream support surface 92. The illustrated blister card
magazine 12 includes walls 100, 102, 104, 106 that are positioned
to constrain the stack of blister cards 14 and the illustrated
sleeve magazine 16 includes walls 110, 112, 114, 116 that are
positioned to constrain the stack of sleeves 18. It is envisaged
that the walls of each magazine 12, 16 can be fixed in different
positions or otherwise adjustable to change the dimensions of the
magazines 12, 16 to accommodate differently dimensioned blister
cards 14 and sleeves 18. Additionally, the plates 20a, 20b can be
adjusted or substituted with differently dimensioned plates.
[0041] Referring to FIGS. 1, 5 and 6, the transversely extending
walls 100, 102, 110, 112 of the parallel magazines 12, 16 do not
extend all the way to the plates 20a, 20b such that the lowermost
blister card 14 and the lowermost sleeve 18 can exit the parallel
magazines 12, 16 in the flow direction F1. The longitudinally
extending walls 104, 106, 114, 116 of the parallel magazines 12, 16
extend to the plates 20a, 20b so as to constrain the movement of
the lowermost blister card 14 and lowermost sleeve 18 to the flow
direction F1. In the illustrated embodiment, the longitudinally
extending walls 104, 106, 114, 116 include openings and detachable
plates 118a, 118b, 120a, 120b (118b, 120b obstructed in FIG. 1)
that facilitate access to the blister cards 14 and sleeves 18, for
example, in the event that the blister cards 14 or sleeves 18 jam
during the loading process.
[0042] Referring to FIGS. 7, and 8, the plates 20a, 20b are spaced
apart to provide a gap 130 therebetween. The plates 20a, 20b are
positioned with respect to the loading conveyor 22 such that a
plane N1, which is substantially perpendicular to the upstream and
downstream support surfaces 90, 92, is at an acute angle with
respect to a plane N2 in which the lugs 24 travel. In other words,
the path P1 of the lugs 24 lies within or is parallel to the plane
N2. With this configuration, a bar code sensor M1 (as shown in FIG.
1) can be positioned to read a target such as the barcode B on the
lowermost blister card 14 through the gap 130 without being
obstructed by the lugs 24 traveling in plane N2. In the illustrated
embodiment, the barcode B is read as the lowermost blister card 14
rests on the upstream support surface 90 prior to being loaded into
the lowermost sleeve 18.
[0043] Referring to FIGS. 1 and 5, empty magazine sensors M2, M3
such as proximity sensors are positioned along the length of the
parallel magazines 12, 16, respectively, to signal when the
magazines 12, 16 are near empty or empty. A blister orientation
sensor M4 such as a proximity sensor is also positioned along the
blister card magazine 12 to signal when a blister card 14 is
incorrectly oriented in the blister card magazine 12. Referring to
FIGS. 9 and 10, the blister card magazine 12 includes an ejecting
structure 132, such as a bar, that cooperates with the chamfered
corner C of the blister card 14. The ejecting structure 132 is
adjacent, without substantially contacting, the chamfered corners C
of blister cards 14 that are properly oriented and contacts and
displaces blister cards 14 that are not properly oriented.
Displaced blister cards 14 are recognized by the blister
orientation sensor M4 and are removed from the blister card
magazine 12, for example, by an operator.
[0044] The loading apparatus 10 includes a metering structure that
is configured to permit a single blister card 14 to be pushed from
the blister card magazine 12 by the lug 24 and to align the blister
card 14 with the corresponding sleeve 18. In alternative
embodiments, the metering structure permits a selected number of
blister cards that is more than one to be pushed from the magazine.
Referring to FIGS. 5-8, and 11, the illustrated metering structure
is a metering block 140 that is positioned at the downstream end of
the upstream support surface 90 and between the parallel magazines
12, 16. The metering block 140 includes a recess 142 that, along
with the upstream support surface 90, provides a metering opening
150 between the lower ends 84, 86 of the magazines 12, 16.
Generally described, the profile of the illustrated metering
opening 150 is dimensioned to fit the profile of the blister card
14 such that only the lowermost blister card 14 to is allowed to
pass through the metering opening 150. Further, the profile of the
recess 142 is tapered to facilitate receiving and aligning the
lowermost blister card 14 as the lowermost blister card 14 moves in
the flow direction F1 through the metering opening 150.
[0045] Referring particularly to FIG. 10, the metering block 140
includes integrally formed guides, although separable elements are
contemplated as well. A center guide 152 and outer edge guides
154a, 154b shape the profile of the recess 142 and extend in
between and adjacent rows of blisters 72 of the lowermost blister
card 14 such that the metering opening 150 is tightly toleranced
around the lowermost blister card 14. Accordingly, the lowermost
blister card 14 is aligned by the metering opening 150. The
upstream ends of the guides 152, 154a, 154b are tapered such that
the leading edge E1 of the lowermost blister card 14 is easily
received the upstream end of the metering opening 150 and, as the
lowermost blister card 14 continues through the metering opening
150, the metering opening 150 narrows around the lowermost blister
card 14. The guides 152, 154a, 154b also function to obstruct the
blister card 14 that rests on the lowermost blister card 14.
[0046] Referring now to FIGS. 6 and 7, the gate 26 is positioned
downstream of and adjacent the lower end 86 of the sleeve magazine
16. FIG. 6 illustrates a first configuration of the gate 26 and
FIG. 7 illustrates a second configuration of the gate 26. Each gate
26 configuration includes a displaceable roller 160 that is
positioned to contact the leading end of the lowermost sleeve 18,
or otherwise the end wall 46, to retain the lowermost sleeve 18 in
the loading position. The roller 160 is displaceable to release the
lowermost sleeve 18 from the loading position. The loading position
can be described as the position at which the open end 48 of the
lowermost sleeve 18 is adjacent the metering opening 150. However,
the lowermost sleeve 18 may be able to slightly shift in the flow
direction F1 before being contacted by the roller 160.
[0047] The roller 160 illustrated in FIG. 6 is connected to a
mechanism that permits the roller 160 to be vertically
displaceable. The roller 160 is rotatably connected to an end of a
rotatable arm 162 by a pin 164. The arm 162 is rotatably connected
between blocks 166a, 166b (166b obstructed in figures) by a pin
168. Accordingly, the roller 160 can displace as the arm 162
rotates about the pin 168 and can rotate about the pin 164 to roll,
for example, along a wall of the lowermost sleeve 18. The blocks
166a, 166b are attached to a basis plate 170 by bolts 172a, 172b.
Stopper bolts 174a, 174b extend through apertures 176a, 176b in the
basis plate 170 to contact opposing ends of the arm 162 to control
the initial and displaced positions of the roller 160. The stopper
bolt 174a has a structure that can be biased or compressed to allow
displacement of the roller 160 and that can be adjusted to control
resistance to displacement of the roller 160. Specifically, the
illustrated stopper bolt 174a has a spring 180, although a
compressible stopper bolt and a flexible arm are contemplated. The
roller 160a illustrated in FIG. 6 has substantially the same
structure and is oriented to be horizontally displaceable.
[0048] In general, the vertically displaceable roller 160 of the
embodiment of FIG. 6 and the horizontally displaceable roller 160a
of the embodiment of FIG. 7 function in substantially the same
manner. However, in the FIG. 6 embodiment, there are frictional
forces between the base wall 42 and the downstream support surface
92 as the roller 160 rolls across the top wall 40. Further, the
roller 160 may crush the top wall 40 of certain sleeve 18 types or
collapse the top wall 40 to crush the blister card 14 therein. In
the FIG. 7 embodiment, the rollers 160a, 160b are positioned on
opposed sides of the lowermost sleeve 18 to reduce frictional
forces on the sleeve 18. Further, since certain sleeve 18 types are
better suited to support loads on the side walls 44a, 44b rather
than on the top wall 40 and base wall 42, positioning the rollers
160a, 160b to roll across the side walls 44a, 44b is advantageous
for such sleeve 18 types. In addition, the position and orientation
of the horizontally displaceable rollers 160a, 160b can allow the
lowermost sleeve 18 to be contacted by the rollers 160a, 160b
further upstream from where the lowermost sleeve 18 would be
contacted by the vertically displaceable roller 160. Thus, the
horizontally displaceable rollers 160a, 160b reduce or eliminate
shifting of the lowermost sleeve 18 during the loading process.
[0049] In the illustrated FIG. 7 embodiment, the roller 160b has a
fixed position and the roller 160a is displaceable. In alternative
embodiments, it is envisaged that each of the rollers 160a, 160b is
displaceable. In addition, a guide roller 160c guides the lowermost
sleeve 18 in the flow direction F1 and prevents contact between the
arm 162a and the lowermost sleeve 18 once the roller 160a and arm
162a are deflected to release the lowermost sleeve 18.
[0050] In other alternative embodiments, a roller may be pinned in
a fixed position and be formed from rubber or urethane or otherwise
have a compressible surface that displaces. In such embodiments,
the elements that provide the spring loaded mechanism can be
omitted. Further, if there is sufficient deformability in the
sleeve 18, a roller may be pinned in a fixed position and made of a
material that is substantially rigid.
[0051] Referring now to FIGS. 1 and 5-8, the loading conveyor 22
includes lugs 24 that can move along the circuit path P1. The
loading conveyor 22 can include carrier chains (not shown) that are
tensioned around sprockets (not shown) and plates that are attached
to the carrier chains to provide a supporting surface. The lugs 24
can be detachably connected to certain of the plates of such a
loading conveyor 22 and the sprockets can be driven by a
servo-motor to move the chains, plates, and lugs 24 along the path
P1. In other embodiments, the lugs 24 can be attached directly to
the carrier chains. It is envisaged that known and yet to be
developed conveyors can be adapted to provide the functionality
described herein.
[0052] The loading conveyor 22 is positioned below and adjacent the
plates 20a, 20b such that the lugs 24 move through the gap 130 in
the flow direction F1 along an operational portion of the path P1.
The distal end 190 of each lug 24 is angled with respect to the
plane N2 so as to be substantially parallel to the plane N1. The
distal end 190 extends into the gap 130, slightly above the
upstream support surface 90 so as to contact only the lowermost
blister card 14, and slightly above the downstream support surface
92 so as to contact only the lowermost sleeve 18. The distal end
190 of the lug 24 includes a notch 192 that corresponds to the
profile of the recess 142 so that the lug 24 is not obstructed by
the metering block 140 as the lug 24 moves through the metering
opening 150. Specifically, the notch 192 is dimensioned and
positioned to avoid contact with the central guide 152. The lug 24
can be alternatively shaped to accommodate other recess 142
profiles.
[0053] As described in further detail below, the speed at which the
loading conveyor 22 moves the lugs 24 along the path P1 can be
constant or variable, for example, so as to follow a cam
profile.
[0054] Referring now to FIGS. 1 and 12, the hopper 27 and the
supply assist apparatus 28 are described in further detail. The
hopper 27 includes a conveyor belt 200 on which sleeves 18 are
placed. The conveyor belt 200 moves the sleeves 18 in a flow
direction F2 along a path toward the upper end 82 of the sleeve
magazine 16. The illustrated hopper 27 includes a support wall 214
that extends along the length of the conveyor belt 200 and
facilitates arranging the sleeves 18 in a line. The sleeves 18 are
placed on the conveyor belt 200 with open ends 48 thereof
configured to face upstream with respect to the flow direction F1
and the end walls 46 of the sleeves 18 substantially abut the
support wall 214. A shell orientation sensor M5 (FIG. 1) is
positioned along the length of the hopper 27 to verify that the
sleeves 18 are properly oriented. In the illustrated embodiment,
the sleeves 18 and the blister cards 14 are properly oriented when
the profiles of the open ends 48 and the end profiles of the
blister cards 14 match up.
[0055] Referring to FIG. 12, the supply assist apparatus 28 is
disposed at the upstream end 216 of the hopper 27, with respect to
the flow direction F2, and includes a supply conveyor 202 and a
back pressure apparatus 204. The supply conveyor 202 includes
plates 206 between which cartons 208 containing sleeves 18 are
loaded. The supply conveyor 202 moves the plates 206 along a path,
the operational portion of which is angled upwardly. The bottom end
of each carton 208 is initially supported by a trailing plate 206
and the top end of each carton 208 is open. Near the upper end of
the operational portion of the path, the plates curve around an end
of the supply conveyor 202 and each carton 208 is overturned such
that the sleeves 18 are supported by a leading plate 206. The
sleeves 18 then rest on the leading plate 206 and the overturned
carton continues to hold the sleeves 18 together as a group. The
leading plate 206 is thereafter positioned to be substantially
coplanar with the hopper 27. Accordingly the overturned carton 208
of sleeves 18 is aligned with the sleeves 18 on the hopper 27.
[0056] The illustrated back pressure apparatus 204 includes a
conveyor 210 with lugs 212 that push the overturned carton 208 of
sleeves 18 from the leading plate 206 in the flow direction F2 to
abut the trailing end of a line of sleeves 18, which may include an
overturned carton 208 of sleeves 18, such that the line of sleeves
18 on the hopper 27 does not topple. Once an overturned carton 208
of sleeves 18 has been pushed onto the hopper 27 and is abutted by
a trailing overturned the carton 208 of sleeves, the leading
overturned carton 208 can be easily removed by an operator so that
the sleeves 18 remain upright and can be moved into the sleeve
magazine 16 by the conveyor belt 200. The back pressure apparatus
204 and the conveyor belt 200 are synchronized to keep the line of
sleeves 18 upright and to move the line of sleeves 18 to the sleeve
magazine 16.
[0057] Referring to FIG. 1, the finishing conveyor 29 is now
described in further detail. The flow direction of the finishing
conveyor 29 is substantially perpendicular to the flow direction
F1. It should be noted that the finishing conveyor 29 can move the
packaged sleeves 18 in the flow direction F2 or against the flow
direction F2. To account for changes in direction, speed, and pitch
between the loading conveyor 22 and the finishing conveyor 29, a
buffer device 220 is positioned therebetween to collect packages
from the loading conveyor 22 and to place the packages on the
finishing conveyor 29. It is contemplated that changes in speed and
direction are useful to interface with, for example, a labeling
apparatus. However, in alternative embodiments, the finishing
conveyor 29 and the loading conveyor 22 can be one in the same or
parallel to one another.
[0058] The illustrated loading apparatus 10 includes an empty pack
sensor M6 and a no-lock sensor M7, each positioned above the
finishing conveyor 29. The empty pack sensor M6 verifies that each
sleeve 18 is loaded with a blister card 14 and the no-lock sensor
M7 verifies that each blister card 14 is fully received and
releasably locked in a sleeve 18.
[0059] An exemplary method of operation of the loading apparatus 10
is now described. Referring to FIG. 1, a stack of blister cards 14
is loaded into the blister card magazine 12 through the upper end
80 and a stack of sleeves 18 is loaded into the sleeve magazine 16
through the upper end 82 by the hopper 27 and supply assist
apparatus 28. When loaded in the parallel magazines 12, 16, the
blister cards 14 and the sleeves 18 are arranged with respect to
one another such that respective ones thereof can be combined.
Specifically, the blister cards 14 are loaded into the blister card
magazine 12 such that the blisters 72 of each blister card 14 face
upwardly and such that the leading edge E1 of each blister card 14
is furthest downstream. The sleeves 18 are loaded into the sleeve
magazine 16 such that the open end 48 of each sleeve 18 faces
upstream with respect to the flow direction F1 or is the trailing
end and such that the base wall 42 is the lowermost wall. Thus, the
leading edges E1 of the blister cards 14 are adjacent the trailing
open ends 48 of the sleeves 18.
[0060] Referring to FIG. 6, as the lowermost blister card 14 is
supported by the upstream support surface 90 and the lowermost
sleeve 18 is supported by the downstream support surface 92, the
lowermost blister card 14 is substantially centered and aligned
with the open end 48 of the sleeve 18 and the metering opening 150.
The upstream support surface 90 is raised with respect to the
downstream support surface 92 such that the leading edge E1 of the
lowermost blister card 14 is not obstructed by the trailing end of
the base wall 42, which is adjacent the open end 48 of the
lowermost sleeve 18.
[0061] Referring to FIGS. 5-8, one of the lugs 42 follows the path
P1 and, along an operational portion of the path P1, enters the
upstream end of the gap 130. As the lug 24 continues along the
length of the gap 130 in the flow direction F1, the distal end 190
of the lug 24 contacts a trailing edge E2 of the lowermost blister
card 14, but does not contact the other blister cards 14 in the
blister card magazine 12. Friction between the lowermost blister
card 14 and the blister card 14 that rests on the lowermost blister
card 14 can apply a pulling force to the resting blister card 14.
However, the profile of the metering opening 150 prevents the
resting blister card 14 from moving through the metering opening
150 along with the lowermost blister card 14.
[0062] The lug 24 continues in the flow direction F1 to push the
lowermost blister card 14 through the metering opening 150, through
the open end 48 and into the compartment 50 of the lowermost sleeve
18. As the lowermost blister card 14 is received in the lowermost
sleeve 18, the roller 160 contacts the end wall 46 to maintain the
position of the lowermost sleeve 18. The retention force provided
by the roller 160 is selected so as to overcome any frictional
forces or contact forces between the lowermost blister card 14 and
the lowermost sleeve 18. In other words, the roller 160 prevents
the pushing force applied by the lug 24 to load the lowermost
blister card 14 into the lowermost sleeve from displacing the
lowermost sleeve 18.
[0063] Once the lowermost blister card 14 is fully received and
releasably locked within the lowermost sleeve 18, the blister card
14 and sleeve 18 are together referred to as a package. The
aperture 74 receives the protrusion 54 to releasably lock the
blister card 14 in the sleeve 18.
[0064] Now that the lug 24 has passed through the metering opening
150, the lug 24 contacts and applies a force to the lowermost
sleeve 18 that is great enough to overcome the retention force
applied by the roller 160. Specifically, as the lug 24 pushes
against the lowermost sleeve 18, the roller 160 is displaced, the
spring 180 is biased or compressed, and the roller 160 rolls across
the top wall 40 of the lowermost sleeve 18 as the lowermost sleeve
continues in the flow direction F1. Once the package is pushed past
the roller 160, the process is repeated for the subsequent
lowermost blister card 14 and sleeve 18. Specifically, the blister
card 14 and sleeve 18 that are now lowermost in the parallel
magazines 12, 16 or are otherwise now supported by the upstream and
downstream support surfaces 90, 92.
[0065] In alternative embodiments, the loading apparatus 10 can
includes a known or yet to be developed vibrator that vibrates the
magazines 12, 16 to facilitate movement of the stacks of blister
cards 14 and sleeves 18 toward the lower ends 84, 86. In still
other alternative embodiments, the metering opening 150 is
configured to permit a predefined number of blister cards 14 to be
loaded substantially simultaneously into a single sleeve 18.
[0066] Referring to an alternative embodiment illustrated in FIG.
12, a loading apparatus 10 includes a gate 26 that is controlled.
The illustrated gate 26 includes a stopper 328 that is connected to
a piston 330. In a closed position, the stopper 328 contacts the
end wall 46 of the lowermost sleeve 18 as the lowermost blister
card 14 is loaded into the lowermost sleeve 18 and retains the
lowermost sleeve 18 in the loading position. In an open position,
the stopper 328 releases the loaded lowermost sleeve 18 from the
loading position. To open the gate 26, the piston 330 is retracted
such that the stopper 328 rotates outwardly about a pin connection
332. To close the gate 26, the piston 330 is extended.
[0067] The rotation of the stopper 328 is timed with respect the
movement of the lugs 24 along the path P1. In the illustrated
embodiment, a controller 334 controls both the piston 330 and a
motor 336 that drives the loading conveyor 22 so as to synchronize
the movement and position of the stopper 328 with the movement and
position of the lugs 24 along the path P1.
[0068] The speed of the lugs 24 along the path P1 can be controlled
so as to be constant or variable. In certain embodiments, it is
beneficial to vary the speed along the length of the path P1 to
prevent damage to the blister cards 14 and sleeves 18 by slowing
the lugs 24 down just before contacting the blister cards 14 and
sleeves 18. Further, the speed can be controlled to slow the lugs
24 down just before contacting the sleeves 18 so as to allow the
stopper 328 more time to clear or open. Along most other lengths of
the path P1, the speed of the lugs 24 is maximized to increase the
efficiency of the loading process.
[0069] The above-described embodiments are merely exemplary
illustrations of implementations set forth for a clear
understanding of the principles of the invention. Variations,
modifications, and combinations may be made to the above-described
embodiments without departing from the scope of the claims. All
such variations, modifications, and combinations are included
herein by the scope of this disclosure and the following
claims.
* * * * *